Section 8 Classification Regulations

8.1.1 Shiplift and transfer systems built in accordance with LR’s Rules in respect of structural and machinery requirements will be eligible for recommendation to the Classification Committee to have a class notation assigned, and will continue to be classed as long as they are found upon examination at the prescribed Surveys to be maintained in accordance with LR’s requirements.

8.1.2 The Regulations for Classification and Periodical Surveys are given in Pt 1 Regulations of LR’s Rules and Regulations for the Classification of Ships. These Regulations will be applied to shiplifts and transfer systems, in so far as they are applicable, and are to be read in conjunction with the specific requirements given in this Chapter.

8.1.3 Where the proposed installation is novel in design, or involves the use of unusual materials, or where experience, in the opinion of the Classification Committee, has not sufficiently justified the principle or mode of application involved, special tests or examinations before and during service may be required. In such cases, the notation will be suitably amended to reflect this.

8.2.1 Shiplift installations and transfer systems, when classed, will be assigned one or both of the following character symbols, as applicable:

	This distinguishing mark will be assigned, at the time of classing, to new installations constructed under LR’s Special Survey, in compliance with the Rules and to the satisfaction of the Classification Committee.
A	This character letter will be assigned to all installations which have been built or have accepted class status in accordance with LR’s Rules and Regulations, and which are maintained in good and efficient condition.

8.2.2 A Class notation will be appended to the character of classification assigned to the installation and this will also indicate whether the transfer system is included in LR’s classification. The character of classification and class notations assigned will, normally, be as follows:

1. A or A – Shiplift for service at ……. (port to be specified); or

2. A or A – Shiplift and transfer system for service at ….. (port to be specified).

8.3.1 Plans for the structural, electrical, mechanical, hydraulic and control engineering aspects of the design are to be submitted for approval. Supporting calculations are to be submitted as required and are to indicate clearly the proposed lifting arrangement for which approval is required. The minimum/maximum design temperatures, maximum operational wind speeds and seismic data are also to be submitted, as appropriate, before the work is commenced. Any subsequent modifications or additions to the scantlings or arrangements shown in the approved plans are also to be submitted for approval.

8.3.2 Upon satisfactory completion of the plan approval, a design appraisal document will be issued for each of the design aspects approved. The design appraisal document for the platform will indicate the designated capacities for which the platform is appraised. The design appraisal document for the hoist unit will state the maximum hoisting capacity of the unit.

8.4.1 New installations are, from the commencement of the work until completion and installation, to be examined by the Surveyor with respect to materials, workmanship and arrangements. The items to be surveyed at the site of manufacture include the platform and transfer system steelwork, hoists and hydraulic cylinders.

8.4.2 Verification is to include the use of approved materials and of those appropriately qualified welders, using approved weld procedures, who are employed during fabrication.

8.4.3 The requirements for weld procedure tests and weld inspection are to be agreed with the Surveyor. In general, however, it is recommended that non-destructive testing of welding to primary members is to be as follows:

1. All fillet and butt welds in the area of support for sheave housings, transverse butt welds in main girders and similar critical areas. Butt welds to have 100 per cent MPI and US examination with 100 per cent MPI on fillet welds.

2. 20 per cent of all other fillet welds in primary structural members to be subject to MPI.

8.4.4 Any items not in accordance with LR’s requirements or the approved plans, or any material, workmanship or arrangement found to be unsatisfactory are to be rectified.

8.4.5 Upon satisfactory fabrication under survey of the platform, cradles, hoists, cylinders, etc. a release note will be issued indicating that the component or components have been fabricated in accordance with the approved plans using approved welding procedures. Any load testing undertaken at the fabrication works prior to dispatch will also be referenced on the release note.

8.5.1 Components fabricated on site are to comply with the requirements of Ch 5, 8.4 Fabrication under Survey of the installation.

8.5.2 After erection on site, the complete facility will be inspected by the attending Surveyor to check that the shiplift and transfer system have been installed in accordance with the approved plans and that any outstanding or remedial work required either at the factory or on site is to be completed satisfactorily.

8.5.3 Once this has been done, load testing and operational testing in accordance with Ch 5, 7.2 Load tests 7.2.4 and Ch 5, 7.3 Operational tests will be carried out.

8.6.1 Periodical Surveys are to be carried out on a 5-yearly Continuous Survey on the basis of the requirements of Ch 5, 8.6 Periodical Surveys 8.6.2.

8.6.2 20 per cent of main and secondary transverse and longitudinal girders are to be examined. This may require the removal of limit switch operating rods to enable submerged areas of the platform to be raised clear of the water. The examination is to include:

1. The connection or seating arrangements at the junction of longitudinal and transverse girders for signs of work hardening and cracking and other defects.

2. A general examination of protective coatings.

3. Examination of the rails for alignment and signs of wear, giving particular attention to connecting arrangements and the connecting rail between the platform and shore.

Decking is to be removed as necessary to allow these examinations.

8.6.3 The Surveyor is to be satisfied with regard to the maintenance condition and lubrication of the hoist ropes. Concurrent with Periodical Surveys, the Surveyor is to carry out a complete in situ visual examination as far as is practicable for signs of corrosion, wear or broken wires:

1. In general, wire ropes are to be renewed where there are 5 per cent or more of broken, worn or corroded wires in any length of ten rope diameters. However, reference is to be made to ISO 4309 in determining specific discarded criteria.

2. At the second Annual Survey and each subsequent year a minimum number of ropes is to be removed from installations as follows:

   Up to 6 hoist units:	1 rope
   8 to 20 hoist units:	2 ropes
   More than 20 hoist units:	4 ropes

   A test to destruction is to be carried out on a sample length selected by the Surveyor from each of the ropes being replaced. Where the test piece fails at breaking loads more than 10 per cent below the minimum required values, consideration will be given to the need to select for test and replacement some or all of the remaining ropes.

3. It is the intention that all ropes be replaced in sequence at a rate determined by wear, chemical attack, corrosion or other forms of deterioration associated with the particular installation. For small installations, this will result in a replacement cycle of about 5 years. Proposals for the replacement cycle for large installations to exceed 10 years will be specially considered in the light of the test results obtained.

8.6.4 Where the Annual Survey incorporates the use of non-destructive examination equipment to inspect hoist ropes, the following procedures are to be adopted:

1. The accuracy and reliability of the NDE equipment is to be demonstrated to the satisfaction of the Surveyor.

2. Field tests are to be carried out to the Surveyor’s satisfaction to verify the suitability of the equipment for the particular hoist and rope arrangement and rope speed.

3. The annual rope Survey is to be as follows:

   1. Complete visual inspection of all ropes for signs of broken wires. Particular attention is to be given to the condition of the ropes in way of the rope terminations as these areas are unlikely to be accessible to NDE equipment. See Ch 5, 8.6 Periodical Surveys 8.6.4.(d) Test A.

   2. NDE of a selected number of ropes using approved equipment operated by skilled personnel. The number of ropes selected for inspection is to be in accordance with Ch 5, 8.6 Periodical Surveys 8.6.3.(b) but not less than 10 per cent of the total number of ropes in the installation. Ropes are to be tested over their full length and are to be selected in accordance with a planned programme of inspection to ensure an even distribution of ropes, selected on an annual rotation basis. See Ch 5, 8.6 Periodical Surveys 8.6.4.(d) Test B.

   3. Two years after installation of the shiplift, one rope that has been subjected to NDE is to be selected for a test to destruction to verify the NDE results. Thereafter, one rope is to be selected for a break test each year. See Ch 5, 8.6 Periodical Surveys 8.6.4.(d) Test C.

4. The results of the tests in Ch 5, 8.6 Periodical Surveys 8.6.4.(c) will be used to determine, to the satisfaction of the Surveyor, whether rope replacement or further testing is necessary for the particular installation. In general, the following criteria are to be used in determining the adequacy of the ropes to be retained in service:

   	Test A
   	The number of broken wires is not to exceed the guidance given in ISO 4309 for the type of rope fitted.
   	Test B
   	The cross-sectional area is not be reduced by more than 10 per cent of the original area. Where the loss in area is found to be between 5 and 10 per cent, consideration is to be given to including these ropes in subsequent examinations in addition to ropes selected for normal annual NDE.
   	Test C
   	The reduction in breaking strength when the combined effect of metal loss, corrosion pitting and broken wires has been taken into account is not to exceed 10 per cent of the minimum specified rope breaking strength. The minimum specified rope breaking strength will be specified by the wire rope manufacturer.

8.6.5 The maintenance, condition and lubrication of hoist chains is to be to the satisfaction of the Surveyor. In general, any length of chain so worn that its mean diameter at its most worn part is reduced by 4 per cent or more from its nominal diameter is to be renewed.

8.6.6 20 per cent of the upper and lower sheaves, bearings, axles and housings are to be examined, with at least two complete sets of sheaves opened up for examination. All sheaves are to be opened up at least once in the 5-yearly Survey cycle. Attention is to be paid to lower blocks in way of drain holes and the attachment of sheave housings to upper and lower supports is to be examined.

8.6.7 Covers on 20 per cent of the hoists are to be removed to allow for the following inspections:

1. The tooth alignment of open gears is to be checked.

2. Main shaft pillow block bearings are to be opened up.

3. Cap screws securing final spur wheels to the drum are to be checked and tightened with a torque spanner.

4. Primary gears and all open gear shafts and bearings are to be examined.

5. The hoist frame and bolting arrangements are to be examined.

8.6.8 Where the transfer system is included in the class notation, 20 per cent of the transfer bogies are to be examined.

1. Wheels are to be examined for wear and the condition of linkages between bogies is to be checked.

2. A random selection of 10 per cent of the axle pins to the bogie wheels is to be withdrawn for inspection for signs of excessive wear and other defects.

3. The rails are to be examined for alignment and signs of wear and to verify the adequacy of the locating and locking arrangements.

8.6.9 An insulation resistance test (megger test) is to be carried out on all electrical systems, and all electrical cables are to be examined. In addition:

1. Breakers, relays and all other mechanical electrical gear are to be examined.

2. 20 per cent of electric motors including bearings and magnetic brakes are to be examined.

3. All circuit-breakers to be tested for overload tripping.

4. Air compressors for hoist ratchet and arrangement are to be generally examined together with the air tank.

5. The efficiency of all safety devices is to be demonstrated.

8.6.10 At a convenient time close to each Periodical Survey, the Surveyor is to attend during a hoist and transfer operation at the facility to check the general operation of the installation.

8.6.11 Decking is not a class matter. However, the general condition of the decking may be reported.

8.6.12 Any other matter which may have a bearing on the class of the installation is also to be reported.

8.6.13 The requirements for Periodical Survey for small installations will be specially considered.

8.7.1 Where classification is desired for a shiplift system not built under Survey, plans and information showing the materials of construction, arrangements and principal scantlings of the platform, hoists, cradles, etc. are to be submitted for approval.

8.7.2 A thorough Survey of the installation is to be carried out and is to include the following:

1. A thorough examination of the steel structure. The scantlings of material present and the extent of any deterioration is to be recorded. Non-destructive testing is to be carried out in accordance with Ch 5, 8.4 Fabrication under Survey of the installation 8.4.3.

2. A thorough examination of all the hoist ropes or chains, together with sheaves and hoist sets. Ropes or chains are to be renewed as may be required by Ch 5, 8.6 Periodical Surveys 8.6.3. The requirements of Ch 5, 8.6 Periodical Surveys 8.6.4.(b) are to be applied and the initial extent of renewal is to be agreed with the Surveyor.

3. A thorough examination of all the hoists and of the electrical and control system in accordance with Ch 5, 8.6 Periodical Surveys 8.6.6, Ch 5, 8.6 Periodical Surveys 8.6.7 and Ch 5, 8.6 Periodical Surveys 8.6.9 respectively.

8.7.3 The installation is to be tested in accordance with Ch 5, 7 Testing.

8.7.4 Where the transfer system is to be included in the Class notation, the requirements of Ch 5, 8.6 Periodical Surveys 8.6.8 are to be complied with, except that 25 per cent of the axle pins to the bogie wheels are to be withdrawn for inspection.

8.8.1 The requirements for certified mechanical lift docks are for classed installations, with the exception of the provisions outlined in Ch 5, 1.4 Certification procedure.